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Power Station - Expansion Joints

Customer: Power Station

Location: South America

Equipment supplied

4 x 4M x 3M Rectangular Expansion Bellows

  • Joint suitable for up to 350°C exhaust gases

2 x 6M x 3M Rectangular Expansion Bellows

  • Joint suitable for up to 350°C exhaust gases


Castle Pumps were contacted by a power station client of theirs who required 6 x rectangular expansion joints for exhaust gases in their power plant. The plant was built in the 1980’s and the expansion joints required replacing which were originally manufactured by Babcock & Wilcox. The lead time for the replacement expansion joints was extended and Castle Pumps were contacted to see if we could provide a solution.


Castle Pumps has strong relationships with an expansion joint manufacturer who manufacture expansion joints for many UK power plants. Drawings were obtained of the expansion joints, which enabled us to adapt the size of our expansion joints to those currently in situ ensuring no design modifications were required to the exhaust system.

As the original expansion joints were designed in the early 80’s an updated design was proposed with double mitre corners, and curved convoluted bellows to reduce the stresses during expansion enabling a design life of over 1000 cycles (over 20 years). The expansion joints also allowed a greater degree of axial movement than the previous design and were supplied complete with 3 year warranty.

Castle Pumps were awarded the order supplying the expansion joints in a quicker lead time than the original manufacturer as well as more competitively. The joints were supplied with a full documentation pack including official drawings, weld procedures, welder qualifications, certificate of compliance, and air blast certificate which were all compiled into a book. Third party inspection was also made available to our client.

The expansion joints were packed to ISPM15 in sturdy sea freight cases with joints wrapped in polyethylene, with any documents in watertight bags. The cases were marked complete with requested client shipping marks and lifting points. 

Castle Pumps are fully accredited to enable you to buy with confidence. Our accreditation includes: Our accreditation A division of the CTS Group, Part of Flow Max Ltd.